Effect of Pyrolysis Reactor on Tire Pyrolysis

The pyrolysis reactor is the heart of the entire tire pyrolysis plant. Its design directly impacts the two key aspects of the pyrolysis process: heat transfer and flow. This influences the pyrolysis reaction rate, energy consumption, product distribution, and equipment lifespan.

Reactor Type	Working Principle	Impact on Tire Pyrolysis	Suitable for:
Batch	The process involves a one-time feed cycle, followed by heating, cooling, and slag discharge.	The batch pyrolysis equipment is simple and the investment is low. However, it has high energy consumption (requiring repeated heating and cooling), low production efficiency, uneven temperatures, large fluctuations in product quality, and a low degree of automation.	Small-scale, initial projects, or pilot production.
Semi-continuous	The feed and gas/oil discharge are continuous, but solid residue (carbon black and steel wire) must be discharged in batches.	Semi-continuous pyrolysis plant has higher thermal and production efficiency than batch processes. However, its structure is more complex than batch processes, and there may be a risk of air ingress during solids discharge.	Medium-scale projects, balancing investment and efficiency.
Continuous	The feed (crushed tire rubber pellets) is continuously fed, and the products (oil, gas, and carbon black) are continuously discharged.	Continuous pyrolysis plant has the highest thermal efficiency, low energy consumption, stable product quality, a high degree of automation, and a large processing capacity. However, it has the most complex equipment structure, the highest investment cost, and requires high control and maintenance requirements.	Large-scale commercial and industrial projects.

Impact of Tire Pyrolysis Equipment Design

Temperature Uniformity and Heating Method

Tire pyrolysis requires a uniform and precisely controlled temperature (typically 450-550°C). Uneven temperatures can lead to overheating and coking of some materials (producing excessive non-condensable gases and carbon black) and incomplete reaction of others (low oil yield).

Direct heating: A flame directly burns the pyrolysis reactor's exterior. This method is cost-effective but offers poor temperature control accuracy, can easily cause local overheating, and shortens the reactor's lifespan.

Indirect heating: The reactor is heated indirectly by heating the hot flue gas or thermal oil within the furnace. This method offers more uniform temperature and precise control, effectively protecting the reactor and is the preferred choice for modern high-quality systems.

Best Practice: Use indirect heating in conjunction with an intelligent temperature control system to control the temperature in zones and ensure a uniform thermal field within the reactor.

Pressure and Sealing

Tyre pyrolysis equipment must be performed in the absence or absence of oxygen, under a slightly negative pressure or at atmospheric pressure. Poor sealing allows air to enter, creating a risk of combustion or even explosion. Furthermore, oxygen can oxidize the products, reducing oil quality and producing more impurities. Excessive pressure can alter the pyrolysis reaction path, affect product distribution, and pose safety risks.

Best Practice: The pyrolysis reactor must utilize high-precision welding techniques and reliable mechanical seals to ensure absolute airtightness throughout the entire system.

Speed ​​and Internal Structure

Many pyrolysis reactors utilize a rotary design. An appropriate speed continuously stirs the material, breaking up surface crusts, significantly improving heat transfer efficiency and ensuring uniform and thorough pyrolysis.

Installing a lifting plate within the pyrolysis reactor further increases the contact area between the material and the hot wall, enhancing thermal efficiency.

Tire Pyrolysis Reactor Material and Durability

The tire pyrolysis environment is extremely demanding, subject to prolonged exposure to high temperatures, a corrosive atmosphere (containing sulfur and chlorine), and friction with solid materials (steel wire).

Ordinary steel will rapidly oxidize, corrode (high-temperature sulfidation corrosion), and wear, shortening equipment life, requiring frequent production stoppages for maintenance, and even leading to safety incidents due to weakened reactor walls.

Best Practice: Use high-temperature-resistant stainless steel (such as 310S) or higher-grade alloy steel. Although the initial cost is high, it can significantly extend the life of the equipment, ensure the stability and safety of long-term operation, and have higher overall benefits.